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Case Studies – How to wrap your headers

Header wrap kicks ass….. when it’s already installed. Yep, nothing worse than wrapping headers or exhaust manifolds, especially when you are wrapping an elaborate one as we will be doing today.

One look at the Talon’s exhaust manifold and it’s quite clear to see that this task isn’t going to be an easy one. Wrapping headers isn’t exactly rocket science, but doing it right is important for aesthetic purposes.

What you will need for this job.

x1 Header wrap – we chose part number DEI-010101 – as this is for a 4 cylinder application. We also elected to use the 1 inch thick version as this wrap is easier for a manifold of this type and usually more pleasing to the eye.

x1 Safety Wire – You can purchase a Moroso can for around 20 dollars.

optional – Safety Wire wrench – you can also use a monkey wrench in a bind, but you wire twists will not look as nice.

Start by cutting off a section that you intend to wrap with, take care when handling the wrap as the fiberglass can come off easily and is a skin and eye irritant.

Dunk your wrap in a container filled with water, this will make the wrapping easier, as well as minimize the dust and fiberglass particles.

When taking your pre-cut strips out of the water, make sure to squeeze any excess water from the bundle. When applying the strips, make sure to pull the wrap taut and wick away any excess moisture when pulling the wrap around the piping.

2 Hours into the job.

Take care when securing the wrap with your safety wire, you want to make sure to get the wire as tight as possible for maximum viewing pleasure.

When wrapping a turbo manifold like this, it’s easier to plot out the path in which you will wrap the header. In this case, I had to wrap runner 4 and leave it hanging to allow for enough tuck room on runner 3.

With the exhaust manifold wrapped, we re-install onto the Talon with a complete set of new washers, gaskets, and seals all the way around.

The Talon had a slight leak from runner #2, and we elected for a Remflex gasket to address our leaking issue.

We are using Remflex part number PN-54-001, and this gasket is every bit as badass as Remflex says it is.

After re-installing the entire turbo setup, the Talon is now ready to hit the dyno after a few gauges are installed.

Next up : Installing a full gauge set, pouring in some 116 and heading to dyno day!